Solid surface composition containing recycled solid surface particles

Abstract

Compositions made from recycled solid surface materials or articles suitable for making solid surface materials or articles, and solid surface materials or articles made therefrom, the compositions comprising a matrix resin of an unsaturated polyester resin, inorganic filler particles, ground solid surface primary particles, ground solid surface secondary particles and optionally solid surface dust particles, the compositions and solid surface materials or articles made therefrom. The present composition is particularly useful for making three-dimensional rigid surface polymer solid surface materials and articles that do not contain undesirable surface voids and have a smooth and stable continuous surface.

Description

Technical Field

[0001] The present invention relates to solid surface materials and articles containing solid surface particles typically obtained from recycling solid surface materials and articles or other sources that are typically waste and will be landfilled, and in particular to decorative panels, countertops, molded articles (e.g., sinks, etc.) and materials and articles suitable for use as other applications.

Background Art

[0002] Various publications mention the recycling of materials. U.S. Patent Application Publication No. 20090104382 discloses composite stone materials including recycled composite stone. The recycled waste can be crushed to any particle size, for example, in the range of about 0.065 mm to 10 mm.

[0003] Korean Patent Application Publication No. 101267653 discloses artificial marble made from recycled acrylic chips with an average particle size of 2 to 40 mm and acrylic chips with a thickness of 5 to 20 mm, with 5 mm or more added.

[0004] Korean Patent Application Publication No. 101581962 discloses a method and apparatus for producing artificial stone made by mixing two or more types of chips with different particle sizes. Examples include chips having a particle size of 3 mm to 9 mm and chips having a particle size of 1 mm to 3 mm.

[0005] Chinese Patent Application Publication No. 102838321 discloses construction waste recycled artificial marble and its preparation method, which is made of the following components: 30 to 70% by weight of construction waste dust, 10 to 50% by weight of fine aggregates recycled from construction waste, 10 to 40% by weight of unsaturated polyester resin, 2 to 15% by weight of accelerator, 0.5 to 4% by weight of curing agent, 0.3 to 4% by weight of acrylic paint, and 0.2 to 4% by weight of aluminum hydroxide.

[0006] Currently, consumers highly value and desire materials that contain a certain amount of recycled materials, particularly post-consumer waste, which is waste generated by consumers of products and considered a recycled material. Manufacturers also desire to recycle the waste generated during the production of products. Recycling any of these types of waste helps reduce the amount of material that must be landfilled and mitigates the environmental impact of building materials.

[0007] Solid surface materials and three-dimensional rigid surface polymer solid materials and articles known as such are sold in many forms including slabs or panels and are suitable for use as kitchen countertops, sinks, wall coverings, various molded articles, and other applications. Solid surface materials are generally composite materials that include a polymer matrix and one or more fillers including inorganic fillers.

[0008] Since solid surface materials typically have filler particles, one potential route for recycling solid surface material scraps was thought to be to grind the solid surface pieces into particles and then use those particles as fillers and combine them with a polymer resin in the production of solid surface materials or articles. Such materials and articles are particularly desirable when containing a high addition amount (50 wt% or more) of recycled solid surface material. However, such recycled materials from post-consumer and manufacturing waste contain many different particle sizes including a significant amount of smaller (<1 mm) particles. It has been found that when a composition for producing a solid surface material contains a high addition amount of such recycled solid surface particles, particularly when a significant amount of smaller (<1 mm) particles are present in the composition, acceptable solid surface materials and articles cannot be obtained. These smaller particles are thought to interact with each other and result in a solid surface material having unacceptable surface voids and / or a rough and / or unstable (crumbly-like) surface touch. Summary of the Invention Problems to be Solved by the Invention

[0009] Accordingly, there is a need for a composition for producing a solid surface material and article having acceptable surface characteristics, which further comprises a substantial amount of smaller (less than 1 mm) particles, preferably a high loading of recycled solid surface particles.

Means for Solving the Problems

[0010] The present invention is a composition suitable for producing a solid surface material or article, a) 15 to 25 wt% (X R ) of an unsaturated polyester resin, and b) ground solid surface primary particles having a particle size that can pass through a mesh screen having an opening of 4.76 mm but cannot pass through a mesh screen having an opening of 0.150 mm, 15 to 50 wt% (X A ) of the ground solid surface primary particles, wherein at least 70 wt% of the ground solid surface primary particles do not pass through a mesh screen having an opening of 0.60 mm, 15 to 50 wt% (X A ) of the ground solid surface primary particles, and c) 30 to 70 wt% (X B ) of fine particles and The particles of c) are i) ground solid surface secondary particles having a particle size that can pass through a mesh screen having an opening of 0.60 mm but cannot pass through a mesh screen size having an opening of 0.075 mm, 2 to 25 wt% (X C ) of the ground solid surface secondary particles, wherein at least 90 wt% of the ground solid surface secondary particles do not pass through a mesh screen having an opening of 0.105 mm, 2 to 25 wt% (X C ) of the ground solid surface secondary particles, and ii) 5 to 35 wt% (X F ) of inorganic filler particles, and iii) having a particle size that can pass through a mesh screen having an opening of 0.150 mm, 0 to 23 wt% (X DSolid surface dust particles, wherein at least 60% by weight of the solid surface dust particles also pass through a mesh screen having an opening of 0.105 mm, 0 to 23% by weight (X D ) of the solid surface dust particles and including, the weight percentage (X C ) of the ground solid surface secondary particles, the lower limit is given by the formula:

Number

Number

Number

Number

Number

Number

[0011] The present invention is a method for producing a solid surface material or article, comprising: A) pulverizing a solid surface article to form a mixture of solid surface particles; B) classifying the particles into a set of classified particles, the set of classified particles comprising: I) ground solid surface primary particles having a particle size that can pass through a mesh screen having an opening of 4.76 mm but cannot pass through a mesh screen having an opening of 0.150 mm, wherein at least 70% by weight of the ground solid surface primary particles do not pass through a mesh screen having an opening of 0.60 mm; and II) ground solid surface secondary particles having a particle size that can pass through a mesh screen having an opening of 0.60 mm but cannot pass through a mesh screen having an opening of 0.075 mm, wherein at least 90% by weight of the ground solid surface secondary particles do not pass through a mesh screen having an opening of 0.105 mm; and the step; C) forming a composition for forming a solid surface article by combining a liquid unsaturated polyester resin with inorganic filler particles and particles selected from the set of classified particles; D) forming the composition into a solid surface article and also relates to a method comprising.

DETAILED DESCRIPTION OF THE INVENTION

[0012] The present invention relates to a composition suitable for producing a solid surface material or article, comprising a matrix resin of an unsaturated polyester resin, inorganic filler particles, ground solid surface primary particles and ground solid surface secondary particles. The composition may contain solid surface dust particles. The present composition is particularly useful for producing three-dimensional rigid surface polymer solid surface materials and articles that do not contain undesirable surface voids and have a smooth and stable continuous surface.

[0013] The composition comprises a matrix resin of 15-25% by weight of an unsaturated polyester resin, 15-50% by weight of ground solid surface primary particles, and 30-70% by weight of fine particles. The 30-70% by weight of fine particles are distributed as follows. 2-25% by weight are ground solid surface secondary particles, 5-35% by weight are inorganic filler particles, 0-23% by weight are solid surface dust particles, and the amount of fine particles is further between a specific upper limit and a lower limit as described by a series of equations relating the upper and lower amounts of each smaller particle. In some preferred embodiments, all of the fine particles pass through a mesh screen having an opening of 0.105 mm.

[0014] In some embodiments, the total amount of ground solid surface primary particles, ground solid surface secondary particles, and any solid surface dust particles constitutes more than 50% by weight of the composition. In some embodiments, the total amount of ground solid surface primary particles, ground solid surface secondary particles, and solid surface dust particles constitutes up to 85% by weight of the composition.

[0015] Specifically, the present invention relates to a composition suitable for making a solid surface material or article and a solid surface material or article made from said composition, the composition comprising a) 15-25% by weight (X R ) of an unsaturated polyester resin, and b) 15-50% by weight (X A ) of ground solid surface primary particles having a particle size that can pass through a mesh screen having an opening of 4.76 mm but cannot pass through a mesh screen having an opening of 0.150 mm, wherein at least 70% by weight of the ground solid surface primary particles do not pass through a mesh screen having an opening of 0.60 mm, 15-50% by weight (X A ) of ground solid surface primary particles, and c) 30-70% by weight (X B ) of fine particles, and the particles of c) i) Particles having a particle size that can pass through a mesh screen having an opening of 0.60 mm but cannot pass through a mesh screen size having an opening of 0.075 mm, 2 to 25% by weight (X C ) of ground solid surface secondary particles, wherein at least 90% by weight of the ground solid surface secondary particles do not pass through a mesh screen having an opening of 0.105 mm, 2 to 25% by weight (X C ) of ground solid surface secondary particles, and ii) 5 to 35% by weight (X F ) of inorganic filler particles, and iii) Particles having a particle size that can pass through a mesh screen having an opening of 0.150 mm, 0 to 23% by weight (X D ) of solid surface dust particles, wherein at least 60% by weight of the solid surface dust particles also pass through a mesh screen having an opening of 0.105 mm, 0 to 23% by weight (X D ) of solid surface dust particles and are included.

[0016] Furthermore, within the above ranges, the inventors have found that particles of different sizes in the composition can interact in a non-linear manner. In particular, when the individual amounts of the smaller particles (ground solid surface secondary particles, any solid surface dust particles, and inorganic filler particles) are further between a specific upper limit and a lower limit as described by a series of equations relating the upper and lower limit amounts of each of the smaller particles to the amount of resin (X R ) and the total amount of fine particles (X B ), it has been found that solid surface materials and articles having the most acceptable surface properties can be obtained, where (X B ) is equal to the sum of (X C ), (X F ) and (X D ).

[0017] Specifically, acceptable solid surface materials and articles are broadly limited by the range of 2 to 25% by weight of the ground solid surface secondary particles in the composition, where the weight % (X C ) is in the range of 2 to 25% by weight, and the weight % (X C) is obtained when it is further between the calculated upper and lower limits that adjust the amount of composition interaction, and the lower limit of the weight % of the pulverized solid surface secondary particles (X C ) is given by the formula:

Number

Number

[0018] The weight % (X F ) of the inorganic filler particles in the composition is widely limited by the range of 5 to 35 weight %, and the weight % (X F ) is further between the calculated upper and lower limits that adjust the amount of composition interaction, and the lower limit of the weight % (X F ) of the inorganic filler particles is given by the formula:

Number

Number

[0019] Solid surface dust particles are any component in the composition, but the weight % (X D ) of the solid surface dust particles in the composition is widely limited by the range of 0 to 23 weight %, and the weight % (X D ) is further between the calculated upper and lower limits that adjust the amount of composition interaction, and the lower limit of the weight % (X D ) of the solid surface dust particles is given by the formula:

Number

Number

[0020] Matrix resin The composition contains 15 - 25 wt% (X R ) of an unsaturated polyester (UPE) resin as the matrix resin. The UPE resin includes a polyester polymer or copolymer incorporating covalently bonded unsaturations such as carbon - carbon double bonds, dissolved in a polymerizable styrenic monomer such as styrene.

[0021] In some embodiments, the unsaturated polyester resin consists essentially of a polyester polymer or copolymer. In some embodiments, the unsaturated polyester resin used in the composition contains about 25 - 90 volume fraction % of unsaturated polyester and 10 - 75 volume fraction % of monomer, where 100% of the monomer is styrene or the monomer is a blend of styrene and methyl methacrylate in any ratio.

[0022] Inorganic filler The composition contains 5 - 35 wt% (X F ) of inorganic filler particles. The inorganic filler particles are solid at room temperature and atmospheric pressure, not chemically decomposed by the various components of the composition, and are insoluble in these components even when these components are raised to temperatures above room temperature, particularly in a curing oven for exothermic curing chemistry. Preferably, the inorganic filler particles are uniformly distributed throughout the composition and any solid surface material or article made from the composition.

[0023] In one embodiment, the inorganic filler particles have a particle size that can pass through a mesh screen with an opening of 0.088 mm.

[0024] In some preferred embodiments, the inorganic filler particles include alumina trihydrate (ATH). Calcined ATH prepared by a heat treatment process to remove water is particularly suitable. In other embodiments, the inorganic filler particles are alumina, talc, or quartz.

[0025] Aluminum trihydrate (ATH) is a preferred inorganic filler in that the ATH matches the refractive index characteristics of the matrix resin and provides a more aesthetically pleasing appearance. By using ATH as a filler, it becomes possible to cut and process the final solid surface material in the same manner as wood, which is generally impossible when using harder fillers.

[0026] The inorganic filler particles and their amounts in the composition refer to the inorganic filler particles intentionally added to the composition, that is, it is intended that the inorganic filler particles are added to and separated from any residual fillers present in the ground solid surface primary particles and secondary particles or solid surface dust particles.

[0027] Solid surface particles The composition contains 15 to 50 wt% (X A ) of ground solid surface primary particles and 2 to 25 wt% (X C ) of ground solid surface secondary particles. The ground solid surface primary particles and secondary particles in the composition are obtained by cutting, kneading and / or grinding scrap solid surface materials or articles into particles. Typically, the scrap solid surface is obtained from locations such as the manufacturing site, the manufacturer of solid surface articles and the demolition of buildings at the end of their service life. The scrap solid surface material or article can be considered to be processed into particles using any convenient crushing or grinding process.

[0028] The ground solid surface primary particles have a particle size distribution that can pass through a mesh screen with an opening of 4.76 mm but cannot pass through a mesh screen with an opening of 0.150 mm, and at least 70 wt% of the ground solid surface primary particles do not pass through a mesh screen with an opening of 0.60 mm.

[0029] The comminuted solid surface secondary particles have a particle size distribution such that they can pass through a mesh screen having an opening of 0.60 mm, but cannot pass through a mesh screen size having an opening of 0.075 mm, and at least 90 wt% of the comminuted solid surface secondary particles do not pass through a mesh screen having an opening of 0.105 mm.

[0030] The comminuted solid surface primary and secondary particles generally include a matrix polymer and a residual filler material such as was contained in the recycled solid surface material or article. This residual filler material can be the inorganic fillers described hereinabove, particularly the alumina trihydrate described above. However, for the purpose of establishing the amounts of materials in the composition, any amount of residual filler material in the solid surface primary and secondary particles or solid surface dust is not considered an "inorganic filler particle" as described herein.

[0031] In some embodiments, the matrix polymer of the comminuted solid surface primary and secondary particles is an acrylic polymer, and in some embodiments, the acrylic polymer includes polymethyl methacrylate. In some embodiments, the comminuted solid surface primary and secondary particles include a mixture of polymethyl methacrylate and an unsaturated polyester polymer.

[0032] Solid surface dust particles Any solid surface dust particles used in the composition are particles having a particle size distribution capable of passing through a mesh screen having an opening of 0.150 mm, and at least 60% by weight of the solid surface dust particles also pass through a mesh screen having an opening of 0.105 mm. The solid surface dust particles are typically generated by wet cutting and polishing operations on solid surface materials and articles. The very fine particles generated can be recovered by filtering the wet cutting and polishing process water and subsequently drying the filter cake captured on the filter. Thus, the solid surface dust particles can include the matrix polymer and residual inorganic filler described above for the primary and secondary particles of the ground solid surface, and can also contain materials added during the particle recovery process, such as a small amount of filter aid or flocculant. In some embodiments, the solid surface dust particles are unground particles. In some embodiments, the solid surface dust particles can include very fine ground particles that are not suitable due to their small size as primary and secondary particles of the ground solid surface.

[0033] Solid surface Next, the matrix resin of the unsaturated polyester resin, the inorganic filler particles, the ground solid surface primary particles, the ground solid surface secondary particles, and any solid surface dust particles can be mixed together to form a free-flowing sand-like composition suitable for making a solid surface material or article. The solid surface material can then be made as described in U.S. Patent No. 3,847,865 to Duggins or U.S. Patent No. 4,085,246 to Buser et al.

[0034] Acceptable solid surface materials and articles can be made from compositions containing recycled materials using conventional casting and molding processes as described herein. However, the inventors have found that some processes are difficult to handle recycled materials in excess of 30% by weight. Above that amount, the composition has a very high viscosity, is difficult to flow and settle in the mold, and acceptable solid surface materials require excessive care.

[0035] The inventors have found that acceptable solid surface materials and articles can be made using a composition containing more than 50% by weight recycled material when the solid surface is made by a vibration compression or vibration compaction process as described in U.S. Patent No. 4,204,820 and / or Italian Patent No. 1,056,388 by Toncelli. These types of processes involve placing the composition in a mold, compressing it while vibrating under vacuum, then transferring the composition in the mold to an oven and subsequently curing the compressed composition to form the solid surface material or article. The cured solid surface material or article, generally in slab form, is then removed from the oven and further processed, if necessary (e.g., trimming the edges, polishing the surface), to produce the finished solid surface material or article.

[0036] Manufacturing method The present invention also relates to a method for manufacturing a solid surface material or article and a solid surface material or article produced thereby, the method comprising A) a step of grinding a solid surface article to form a mixture of solid surface particles; B) a step of classifying the particles into a set of classified particles, the set of classified particles comprising I) ground solid surface primary particles having a particle size that can pass through a mesh screen having an opening of 4.76 mm but cannot pass through a mesh screen having an opening of 0.150 mm, wherein at least 70% by weight of the ground solid surface primary particles do not pass through a mesh screen having an opening of 0.60 mm; II) ground solid surface secondary particles having a particle size that can pass through a mesh screen having an opening of 0.60 mm but cannot pass through a mesh screen size having an opening of 0.075 mm, wherein at least 90% by weight of the ground solid surface secondary particles do not pass through a mesh screen having an opening of 0.105 mm; and a step; C) forming a composition for forming a solid surface article by combining a liquid unsaturated polyester resin with particles selected from a set of classified particles together with inorganic filler particles; D) shaping the composition into a solid surface article; and including.

[0037] It is considered that the grinding step A) can be carried out via many different types of size reduction devices including devices such as hammer mills, disk mills, and roll mills. If necessary, various devices can be combined to cut, knead, and / or grind the scrap solid surface material or article into the desired particles.

[0038] It is further considered that any industrial method of sieving particles using a sieve can be used in the classification step B). A typical method of sieving particles uses a column of sieve trays of stepped mesh sizes. The particles to be classified are poured onto the upper sieve tray with the largest sieve openings. The openings of each lower sieve tray in the column are smaller than the above openings.

[0039] The column of sieve trays is typically placed in a mechanical shaker, which shakes all the sieve trays in the column to promote the movement of the particles on the surface of each mesh screen in each tray, so that particles small enough to pass through the screen openings can fall by gravity to the next sieve tray. After the shaking is complete, the particles remaining on each mesh screen of each sieve tray have a particle size that is too large to pass through the openings of that mesh screen. Thus, the classification step B) obtains a particle size distribution and separates those particles into specific size cuts of each particle size, where each cut has a size that passes through a mesh screen with a larger opening but does not pass through a mesh screen with a smaller opening. In some embodiments, the column of sieve trays has a plurality of sieve trays, and each sieve tray has a screen mesh with a set opening dimension.

[0040] There are various systems for identifying mesh sizes such as US standard mesh or Tyler mesh. In this specification, to avoid confusion, any screen size is identified by the opening in millimeters. Additionally, as used in this specification, the opening of the screen is assumed to be a square opening. For example, a mesh screen with an opening of 0.150 mm has a square opening, and each side of the square opening is nominally 0.150 mm.

[0041] Preferably, the column of sieve trays includes at least five sieve trays, each sieve tray having openings of different sizes, arranged in order from the screen with the largest opening at the top to the screen with the next largest opening, and so on. The pan is used to collect any particles that pass through all the screens. In some embodiments, the screen mesh openings of the tray column range from about 4.76 mm to 0.075 mm. Representative nominal screen mesh openings for classifying particles can include 4.76 mm, 0.6 mm, 0.150 mm, 0.105 mm, 0.088 mm, and 0.075 mm.

[0042] Step C) of producing a composition suitable for making a solid surface material or article by combining an unsaturated polyester resin with particles can be achieved using the methods described in U.S. Patent No. 3,847,865 or U.S. Patent No. 4,085,246 by Buser et al.

[0043] In some embodiments, step C) of combining the unsaturated polyester resin with the particles can be achieved by first combining the resin with various desired additives, typically other liquid components such as coupling agents and / or catalysts, and then mixing to form a resin mixture. Separately, the primary particles and secondary particles can be combined and mixed, and then the resin mixture can be added to this particle mixture and mixed until a uniform mixture is obtained. At this point, if the composition contains such particles, an inorganic filler can be added along with any solid surface dust particles, and all materials are appropriately dispersed as needed and the entire mixture is further mixed until the mixture has the consistency of wet sand.

[0044] In some embodiments, a method of making a solid surface material or article uses a composition in step C) that contains more than 50% by weight of particles selected from a set of classified particles.

[0045] In some embodiments of the method, step C) further includes a step of combining solid surface dust particles in the composition for forming a solid surface article, the solid surface dust particles having a particle size that can pass through a mesh screen having an opening of 0.150 mm, and at least 60% by weight of the solid surface dust particles also pass through a mesh screen having an opening of 0.105 mm.

[0046] In some embodiments, a method of making a solid surface material or article uses a composition in step C), and the total amount of particles selected from ground solid surface primary particles, ground solid surface secondary particles, and solid surface dust particles constitutes more than 50% by weight of the composition. In still other embodiments, a method of making a solid surface material or article uses a composition that contains up to 85% by weight of particles selected from the total amount of ground solid surface primary particles, ground solid surface secondary particles, and solid surface dust particles.

[0047] In some embodiments, a method of making a solid surface material or article uses a composition in step C) that contains 15 - 25% by weight of a liquid polyester resin.

[0048] In some embodiments, the method of making a solid surface material or article uses a composition of step C) comprising 15-25 wt% of an unsaturated polyester resin as the matrix resin, 15-50 wt% of ground solid surface primary particles, and 30-70 wt% of fine particles. The 30-70 wt% of fine particles are distributed as follows. 2-25 wt% are ground solid surface secondary particles, 5-35 wt% are inorganic filler particles, and 0-23 wt% are solid surface dust particles. Preferably, all of the fine particles pass through a mesh screen having an opening of 1 mm.

[0049] In some embodiments, the method of making a solid surface material or article uses the composition of step C) that addresses non-linear particle interactions and creates the most acceptable surface properties, as previously described herein. Specifically, in some embodiments, the method of making a solid surface material or article a) 15-25 wt% (X R ) of an unsaturated polyester resin, and b) 15-50 wt% (X A ) of ground solid surface primary particles, and c) 30-70 wt% (X B ) of fine particles and uses a composition of step C) comprising, and the particles of c) i) 2-20 wt% (X C ) of ground solid surface secondary particles, and ii) 5-35 wt% (X F ) of inorganic filler particles, and iii) 0-23 wt% (X D ) of solid surface dust particles having a particle size capable of passing through a mesh screen having an opening of 0.150 mm, wherein at least 60 wt% of the solid surface dust particles also pass through a mesh screen having an opening of 0.105 mm, 0-23 wt% (X D ) of solid surface dust particles and comprising.

[0050] Furthermore, within the ranges provided above and described in a) - c) and i) - iii) hereinbefore, the inventors have found that particles of different sizes in the composition can interact in a non - linear manner, and the individual amounts of the smaller particles (ground solid - surface secondary particles, any solid - surface dust particles, and inorganic filler particles) are such that when there is further between a specific upper limit and a lower limit, as described by a series of equations relating the upper and lower limit amounts of each of the smaller particles to the amount of resin (X R ) and the total amount of the fine particles (X B ), solid - surface materials and articles having the most acceptable surface characteristics can be obtained, where (X B ) is equal to the sum of (X C ), (X F ) and (X D ).

[0051] Specifically, acceptable solid - surface materials and articles are broadly limited by a range where the weight percentage (X C ) of the ground solid - surface secondary particles in the composition is in the range of 2 - 25 wt%, and are obtained when the weight percentage (X C ) is further between the calculated upper and lower limits that adjust the amount of composition interaction. The lower limit (X C ) of the weight percentage of the ground solid - surface secondary particles is represented by the formula:

Number

Number

[0052] The weight percentage (X F ) of the inorganic filler particles in the composition is broadly limited by a range of 5 - 35 wt%, the weight percentage (X F ) is further between the calculated upper and lower limits that adjust the amount of composition interaction, and the lower limit of the weight percentage (X F ) of the inorganic filler particles is represented by the formula:

Number

Number

[0053] Solid surface dust particles are an optional component in the composition, but the weight % (X D ) of solid surface dust particles in the composition is widely limited by the range of 0 to 23 wt%, and the weight % (X D ) is further between the calculated upper and lower limits that adjust the amount of composition interaction. The lower limit of the weight % (X D ) is given by the formula:

Number

Number

[0054] In some embodiments, the method of making a solid surface material or article uses the composition of step C) that includes inorganic filler particles having a particle size capable of passing through a mesh screen having an opening of 0.088 mm.

[0055] Then, the composition made in step C) is preferably poured into a mold or otherwise transferred to make a slab or other article of a solid surface material containing recycled material.

[0056] In some embodiments, the shaping in step D) of the composition is carried out under heat and pressure, and in some embodiments, the method described in U.S. Patent No. 3,847,865 by Duggins can be used. In some embodiments, the method may include one or more steps of vibration and / or vacuum. As previously described herein, one preferred method of shaping in step D) is to use a vibration compression or vibration compaction process as described in U.S. Patent No. 4,204,820 and / or Italian Patent No. 1,056,388 by Toncelli. These types of processes include steps of placing the composition in a mold and then simultaneously vibrating and compressing the composition while degassing the composition by vacuum within the mold. The compressed composition is then cured in an oven to produce a solid surface material or a solid surface material article, generally in slab form.

[0057] The amount of vacuum required to degas the composition depends on the actual composition and the type of equipment used, but a vacuum above 5 mbar can be used for rapid degassing (e.g., less than 2 minutes). The composition is generally shaped and compressed at room temperature and then heat is typically applied in an oven at about 80 °C to 120 °C to cure the composition into a solid surface material and / or article.

Examples

[0058] In the following examples, samples of the solid surface were made from a composition containing the following components. The matrix resin was an unsaturated polyester (UPE) resin (Ineos Composites Polaris® resin). The additive components were a coupling agent (Silane A-174) and a peroxide catalyst (Norox® 410-50 OMS). The inorganic filler was Chalco® 15 alumina trihydrate (ATH), which had a particle size range of about 4 to 160 microns and a D50 of 15 microns.

[0059] The primary particles and secondary particles were particles obtained by pulverizing and classifying an acrylic solid surface. The primary particles had a particle size such that they could pass through a 4.76 mm mesh size screen but could not pass through a 0.150 mm mesh size screen, and 71 wt% of these particles could not pass through a 0.60 mm mesh size screen. The secondary particles had a particle size such that they could pass through a 0.60 mm mesh size screen but could not pass through a 0.075 mm mesh screen size, and 96 wt% of these particles could not pass through a 0.105 mm mesh screen size. The solid surface dust particles were small particles obtained from wet cutting and polishing operations, then captured as a filter cake on a filter and subsequently dried to have a particle size that could pass through a 0.150 mm mesh size screen, and 73 wt% of the particles obtained passed through a 0.105 mm mesh size screen.

[0060] All of the compositions were prepared in the laboratory using laboratory equipment in the following manner. The UPE resin and the coupling agent were combined and then mixed for 2 minutes, followed by the addition of the catalyst, and these liquid components were further mixed for 2 minutes. Then, this resin mixture was removed. Next, the primary particles and secondary particles were combined and mixed for 2 minutes at a mixing speed of 48 Hz. Then, while mixing at a mixing speed of 15 Hz, the resin mixture was added to the combination of primary and secondary particles, and then the entire mixture was stirred for a further 2 minutes at a mixing speed of 48 Hz. Then, the solid surface dust particles and alumina trihydrate were added to the mixture while mixing at a mixing speed of 15 Hz, followed by further mixing for 2 minutes at a mixing speed of 48 Hz. Each composition mixture had the consistency of wet sand.

[0061] Next, each composition mixture was poured into a mold, and while the mold was also pressed inside the mold, the mold was placed in a vibration compression unit under a vacuum of 9 mbar for 90 seconds, specifically pressed under a pressure of 40 psi for 25 seconds, and then pressed under a pressure of 30 psi for 65 seconds. Next, the mold was transferred to an oven and cured at 100 °C for 90 minutes, and then cooled to form a sample of the solid surface material.

[0062] Examples 1 to 4 are examples of the present invention, while Examples A to D are comparative examples, both prepared from the compositions shown in Tables 1 and 2.

[0063] [Table 1]

[0064] [Table 2]

[0065] As shown in Table 2, all of Examples 1 to 4 of the present invention have weight fractions within the broader ranges provided herein, and these weight fractions are also within the upper and lower limits provided by the formulas provided herein, and these upper and lower limits compensate for the interaction of the smaller particles in the composition during molding. Subsequently, the samples of the solid surfaces molded from the compositions of Examples 1 to 4 had acceptable surface characteristics having both a stable and smooth continuous surface without unacceptable surface voids.

[0066] Comparative Examples A to D had weight fractions outside the broader ranges provided herein, or these weight fractions deviated from one or more of the upper and lower limits provided by the formulas provided herein. In Table 2, the weight fractions indicated by an asterisk (*) are outside the desired ranges. As a result, the samples of the solid surfaces molded from the compositions of Comparative Examples A to D did not have acceptable surface characteristics, and these samples had either unacceptable surface voids or a brittle and granular unstable surface or both.

[0067] Furthermore, Table 3 further shows that acceptable solid surface materials and articles can be made where the majority of the material is recycled material. Combining the data amounts from Table 1, the recycled material was the total amount of ground solid surface primary particles, ground solid surface secondary particles, and any solid surface dust particles. Fillers and additives were also combined. As shown in Table 3, Examples 1, 3, and 4 all produced acceptable solid surfaces, all made from a combination of ground solid surface primary particles, ground solid surface secondary particles, and any solid surface dust particles, with the total amount being over 50 wt% of the composition.

[0068]

Table 3

Claims

1. A composition suitable for producing solid surface materials or articles, a) 15-25% by weight (X R ) an unsaturated polyester resin, b) A particle size that can pass through a mesh screen with an opening of 4.76 mm but cannot pass through a mesh screen with an opening of 0.150 mm, 15 to 50% by weight (X A ) pulverized solid surface primary particles, wherein at least 70% by weight of the pulverized solid surface primary particles are 15-50% by weight (X) that do not pass through a mesh screen having an opening of 0.60 mm. A ) pulverized solid surface primary particles, c) 30-70% by weight (X B ) fine particles and The particles in c) include, i) A particle size that can pass through a mesh screen with an opening of 0.60 mm but cannot pass through a mesh screen with an opening of 0.075 mm, 2 to 25% by weight (X C ) pulverized solid surface secondary particles, wherein at least 90% by weight of the pulverized solid surface secondary particles are 2 to 25% by weight (X) that do not pass through a mesh screen having an opening of 0.105 mm. C ) and crushed solid surface secondary particles, ii) 5-35% by weight (X F ) inorganic filler particles, iii) Solid surface dust particles having a particle size that can pass through a mesh screen having an opening of 0.150 mm, 0 to 23% by weight (X D ) of which at least 60% by weight of the solid surface dust particles also pass through a mesh screen having an opening of 0.105 mm, 0 to 23% by weight (X D ) of solid surface dust particles and Includes, and the weight % (X) of crushed solid surface secondary particles C The lower limit of ) is given by: [Math 1] Further expressed by and the weight % (X) of the crushed solid surface secondary particles C The upper limit of ) is given by the formula: [Math 2] It is further expressed by the weight % (X) of inorganic filler particles. F The lower limit of ) is given by: [Math 3] It is further expressed by and the weight % (X) of inorganic filler particles. F The upper limit of ) is given by the formula: [Math 4] It is further expressed by, if solid surface dust particles are present, the weight % of solid surface dust particles (X D The lower limit of ) is given by: [Math 5] It is further expressed by and the weight % (X) of solid surface dust particles. D The upper limit of ) is given by the formula: [Math 6] A composition further represented by

2. The composition according to claim 1, wherein the inorganic filler particles have a particle size that can pass through a mesh screen having an opening of 0.088 mm.

3. The composition according to claim 1, wherein the inorganic filler is alumina trihydrate.

4. The composition according to claim 1, wherein a combination of crushed primary solid surface particles, crushed secondary solid surface particles, and any solid surface dust particles constitutes more than 50% by weight of the composition.

5. The composition according to claim 4, wherein the combination of crushed solid surface primary particles, crushed solid surface secondary particles, and solid surface dust particles constitutes up to 85% by weight of the composition.

6. A solid surface material or article comprising the composition described in any one of claims 1 to 5.

7. A method for producing a solid surface material or article, A) A step of crushing a solid surface article to form a mixture of solid surface particles, B) A step of classifying the particles into a set of classified particles, wherein the set of classified particles is: I) Crushed solid surface primary particles having a particle size that can pass through a mesh screen having an opening of 4.76 mm but cannot pass through a mesh screen having an opening of 0.150 mm, wherein at least 70% by weight of the crushed solid surface primary particles are crushed solid surface primary particles that do not pass through a mesh screen having an opening of 0.60 mm, II) Crushed solid surface secondary particles having a particle size that can pass through a mesh screen having an opening of 0.60 mm but cannot pass through a mesh screen having an opening of 0.075 mm, wherein at least 90% by weight of the crushed solid surface secondary particles are crushed solid surface secondary particles that do not pass through a mesh screen having an opening of 0.105 mm Processes including, C) A step of forming a composition for forming a solid surface article by combining a liquid unsaturated polyester resin with inorganic filler particles and particles selected from the classified set of particles, D) A step of forming the composition into a solid surface article. A method that includes this.

8. The composition suitable for producing a solid surface article, which is produced in step C), is a) 15-25% by weight (X R ) an unsaturated polyester resin, b) 15-50% by weight (X A ) pulverized solid surface primary particles, c) 30-70% by weight (X B ) fine particles and The particles in c) include, i) 2-20% by weight (X C ) and crushed solid surface secondary particles, ii) 5-35% by weight (X F ) inorganic filler particles, iii) A particle size having a diameter that can pass through a mesh screen with an opening of 0.150 mm, 0 to 23% by weight (X D ) Solid surface dust particles, wherein at least 60% by weight of the solid surface dust particles also pass through a mesh screen having an opening of 0.105 mm, and 0 to 23% by weight (X D ) Solid surface dust particles and Includes, and the weight % (X) of crushed solid surface secondary particles C The lower limit of ) is given by: [Number 7] Further expressed by and the weight % (X) of the crushed solid surface secondary particles C The upper limit of ) is given by the formula: [Number 8] It is further expressed by the weight % (X) of inorganic filler particles. F The lower limit of ) is given by: [Number 9] It is further expressed by and the weight % (X) of inorganic filler particles. F The upper limit of ) is given by the formula: [Number 10] It is further expressed by, if solid surface dust particles are present, the weight % of solid surface dust particles (X D The lower limit of ) is given by: [Math 11] It is further expressed by and the weight % (X) of solid surface dust particles. D The upper limit of ) is given by the formula: [Math 12] The method according to claim 7, as further represented by [the present invention].

9. A solid surface material or article manufactured by the method described in claim 7 or claim 8.

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